Renault Koleos Service Repair Manual: High pressure pipe between rail and injector: Removal - Refitting

Renault Koleos Service Repair Manual / Engine and peripherals / Diesel injection / High pressure pipe between rail and injector: Removal - Refitting

M9R

Diesel injection

IMPORTANT Consult the safety and cleanliness advice and operation recommendations before carrying out any repair.

 

IMPORTANT Use the diagnostic tool before any operation is carried out on the injection circuit to check:
  • that the rail is not under pressure,
  • that the fuel temperature is not too high.

Working on the circuit with the engine running is strictly forbidden.

 

IMPORTANT During this operation, be sure to:
  • refrain from smoking or bringing red hot objects close to the working area,
  • be careful of fuel splashes when disconnecting the union.

 

WARNING To avoid any corrosion or damage, protect the areas on which fuel is likely to run.

REMOVAL

I - REMOVAL PREPARATION OPERATION

  • Remove the front engine cover.
  • Disconnect the battery.

Diesel injection

  • Rotate the intercooler air inlet pipe clip (1) on the turbocharger.

Diesel injection

  • Remove the intercooler air inlet pipe bolt (2) from the fuel pipe support.
  • Move the intercooler air inlet pipe to one side.

Diesel injection

  • Remove:
    • the protector plate (3) from the injector rail protector
    • the injector rail protector
    •  the oil separator
    • the diesel injector fuel return rail

II - OPERATION FOR REMOVAL OF PART CONCERNED

Diesel injection

Note: Loosen the pipe nuts one by one.

 

Note: Do not allow any diesel fuel to enter the engine via the rocker cover opening during this operation.
  • Undo:
    • the high pressure pipe nuts on the injectors using a 17 mm long lever spanner, part number 77 11 223 720,
    • the high pressure pipe nuts on the injector rail using
    • 19 mm long lever spanner, part number 77 11 223 721.
  • Remove the high pressure pipes between the rail and the injectors one by one.
  • Insert the blanking plugs.

REFITTING

I - REFITTING PREPARATION OPERATION

  • Always replace:
    • the high pressure pipes between the injector rail and the injectors,
    • the intercooler air inlet pipe seal.
WARNING Before fitting a new high pressure pipe, lightly lubricate the nut threads with the oil from the applicator provided in the new parts kit.

Be careful not to allow oil into the high pressure pipe.

Do not lubricate high pressure pipes supplied without an applicator, as these high pressure pipes are self-lubricating.

 

WARNING Do not remove the blanking plugs from each component until the last moment.

Also, do not remove the components from their packaging until they are to be fitted to the vehicle.

II - REFITTING OPERATION FOR PART CONCERNED

  • Remove the blanking plugs.
Note: Tighten the high pressure pipes between the rail and the injectors one by one.
  • Fit:
    • the high pressure pipe olives between the rail and the injectors in the injector rail tapers,
    • the high pressure pipe olives between the rail and the injectors in the injector tapers.
  • Manually tighten the high pressure pipe nuts between the rail and the injectors, starting with the nuts on the injector rail side.
  • Torque tighten:
    • the high pressure pipe nuts on the injectors (32 N.m) using a 17 mm long lever spanner, part number 77 11 223 720,
    • the high pressure pipe nuts on the injector rail (32 N.m) using a 19 mm long lever spanner, part number 77 11 223 721.

III - FINAL OPERATION

  • Refit:
    • the diesel injector fuel return rail
    • the oil separator
    • the injector rail protector.

Diesel injection

  • Remove the intercooler air inlet pipe seal using a tweezers.

Diesel injection

Note: Check that the seal (4) on the intercooler air inlet pipe is fitted the correct way round.
  • Refit:
    • the new seal of the intercooler air inlet pipe,
    • the protector plate on the injector rail protector.
  • Turn the intercooler air inlet pipe to refit the clip in its housing.
  • Clip the intercooler air inlet pipe onto the turbocharger.
  • Refit the intercooler air inlet pipe bolt on the fuel pipe support.
  • Torque tighten the intercooler air inlet pipe bolt (8 N.m).
  • Connect the battery.
  • Prime the fuel circuit using the manual priming pump.
  • Refit the engine cover.
    High pressure pipe between pump and rail: Removal - Refitting

    Injector rail: Removal - Refitting

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